Hardware modules tailored for OEM flexibility

Modular slices scale IO density and communication buses without sacrificing cabinet space. Redundant power supplies and hot-swappable IO keep uptime high.

CPU & Processing

Quad-core processor with hardware acceleration for motion and safety tasks. 64 MB program memory, 256 MB data storage, SD card expansion.

  • Dual Ethernet ports (RJ45 + SFP)
  • Native OPC UA/MQTT
  • Secure boot & TPM 2.0

IO Slices

Digital, analog, and specialty IO slices with removable terminals. Hot-swap support allows maintenance without shutting down drives.

  • Up to 1,024 IO points
  • HART, RTD, thermocouple modules
  • Safety IO with PROFIsafe

Communication Gateways

Plug-in gateways support EtherNet/IP, PROFINET, EtherCAT, Modbus TCP, BACnet/IP, and serial protocols for legacy equipment.

  • Redundant ring topologies
  • Edge gateway for cloud analytics
  • Modem options for remote sites

Development Environment

Danfoss Automation Studio with IEC 61131-3 languages, PLCopen motion blocks, version control, and simulation tools.

  • Integrated digital twin
  • Git-based revision control
  • Automated regression testing

HVAC heritage hardened for industrial duty

The Danfoss PLC adapts its HVAC control lineage with environmental, safety, and connectivity upgrades that satisfy OEM production requirements.

Focus area HVAC baseline Industrial adaptation
Environmental resilience 0–40°C operation, office-grade enclosures -25–60°C rating, conformal coating, vibration-resistant chassis
Safety architecture Basic STO integration for AHU drives Integrated PROFIsafe/FSOE, dual-channel safety CPU, SIL3 diagnostics
Industrial networking BACnet/IP and Modbus TCP connectivity Deterministic EtherCAT, PROFINET IRT, redundant ring topologies
Redundancy & uptime Single power supply, limited hot-swap capability Dual hot-swappable supplies, mirrored SD storage, bumpless task switchover
Service windows Manual firmware updates, ad-hoc backups Automated patch staging, remote snapshots, DrivePro® lifecycle alignment

Industrial certification pathway

Documentation bundle mapping PLC hardware to UL, CE, and CSA requirements with test plans and manufacturer certificates.

  • UL 508C, UL 61010, IEC 61131 references
  • Panel derating and enclosure calculations
  • Factory witness checklist templates

Industrial firmware roadmap

Quarterly bulletins align HVAC-derived firmware updates with OEM regression testing and deployment slots.

  • Change impact summaries for PLC and drive libraries
  • Automated test scripts for safety and motion blocks
  • Rollback plans tied to backup snapshots

Service integration kit

Guides service teams on remote diagnostics, log collection, and DrivePro® escalation using the Danfoss PLC platform.

  • Secure remote access playbooks
  • Alarm and trend tagging standards
  • SLA-based escalation matrices
Industrialization gates

Govern every PLC release with measurable checkpoints

Gross Automation guides OEM teams through a four-gate process so Danfoss PLC deployments meet industrial expectations for reliability, cybersecurity, and lifecycle governance.

  • Every gate documents owners, deliverables, and KPIs so stage exits are objective.
  • Command center analysts join hardware engineers to keep DrivePro® telemetry ready for launch.
  • Gate outputs feed resource kits, calculators, and support runbooks in your OEM portal.

Gate 1 — Assess & align

We baseline the installed control architecture, document mechanical requirements, and capture cybersecurity policies so Danfoss PLC hardware starts with a complete engineering dossier.

  • Requirements workshop synthesizes PLC IO, motion, and safety expectations.
  • Lifecycle review maps DrivePro® data to OEM KPIs and modernization goals.
  • Risk register prioritizes firmware alignment, spare strategies, and training needs.
Primary owner
OEM controls lead + Gross Automation solutions engineer
Outputs
Requirements dossier, cyber baseline, modernization timeline

Ready to align your PLC roadmap with our engineering gates?

Book a PLC stage-gate review
Gross Automation labs

Validation environments engineered around Danfoss PLC rollouts

Gross Automation is the best because we prove every Danfoss PLC strategy in our own labs before it reaches your factory floor. Command center analysts, fabrication engineers, and field specialists collaborate through shared infrastructure so lessons learned feed your launch.

  • Real hardware-in-the-loop cells exercising PLC code, drive libraries, and network performance.
  • Lifecycle dashboards linking command center data to PLC firmware staging and backups.
  • Regional depots that rehearse recovery sequences with your documentation and spares.
Fabrication & test

Industrial validation cells

PLC staging racks mirror Danfoss drives, safety IO, and network topologies so code and diagnostics are proven under load before shipment.

  • UL508A lines with drive load banks and environmental stress testing.
  • Digital twin capture ensures PLC and HMI images align with production hardware.
  • Remote witness streams allow OEM teams to review test evidence in real time.
Command center

Readiness coordination

Our Germantown command center tracks firmware, risk, and spare strategies so PLC deployments and lifecycle support stay synchronized.

  • DrivePro®, historian, and PLC telemetry consolidated for launch scorecards.
  • Mitigation playbooks tie engineering, fabrication, and field owners to each risk.
  • Executive updates summarize readiness KPIs for OEM leadership teams.
Field depots

Commissioning rehearsal

Regional teams stage Danfoss PLC cabinets, spares, and recovery kits so onsite crews can simulate startup, failover, and service workflows.

  • Pre-loaded PLC images matched to your revision control and security policies.
  • Rapid-response spare kits and mobile fabrication carts for retrofit windows.
  • Bilingual specialists supporting cross-border startups and documentation.
Motion Coordination

Unified drive & PLC motion libraries

Pre-tested function blocks harmonize Danfoss VLT®/VACON® drives with servo axes for packaging, material handling, HVAC, and water processes. Our libraries accelerate deployment while keeping customization flexible.

  • PLCopen-compliant motion blocks for cams, gearing, and position control.
  • Integrated Safe Limited Speed, Safe Stop, and Safe Position with Danfoss drives.
  • Pre-tuned PID, energy optimization, and pump staging algorithms.
  • Drive parameter synchronization with PLC tag databases.
  • Simulation-ready templates for Factory Acceptance Testing.

Motion toolkit

Axis commissioning workbook Servo sizing calculator Conveyor coordination blueprint

Supported motion interfaces

  • EtherCAT FSoE
  • PROFINET IRT
  • POWERLINK
  • CANopen DS402

Cybersecurity posture

Danfoss PLC security is engineered around IEC 62443. Gross Automation hardens deployments with layered defenses and monitoring.

  • Role-based access controls, Active Directory integration, and multi-factor authentication.
  • Signed firmware, secure boot, and encrypted communications.
  • Network segmentation templates aligning IT/OT domains with zero-trust methodologies.
  • Vulnerability scanning and patch validation through DrivePro® Lifecycle services.
  • Incident response playbooks for OEM service teams.
Lifecycle governance

Planned firmware and asset management

We maintain shared visibility into firmware roadmaps, lifecycle milestones, and spare part strategies so OEM fleets remain supported over a decade or more.

  • Firmware release notifications and regression validation reports.
  • Digital twin backups for rapid disaster recovery.
  • DrivePro® Extended Warranty alignment with PLC spares.
  • Optional managed services for remote diagnostics and analytics.
Explore lifecycle services

Co-engineering workflow

Our senior electrical engineers engage from concept through launch, ensuring PLC and drive architectures are validated against safety, performance, and maintainability targets.

01

Requirements alignment

Joint workshops covering IO counts, motion axes, safety levels, and data strategy. Deliverable: application requirements brief.

02

Architecture design

PLC hardware selection, network topology, drive pairing, and panel layout concept delivered with simulation parameters.

03

Code template build

Custom function blocks, HMI screens, and diagnostics built using Git-based workflows with OEM review checkpoints.

04

Factory acceptance & commissioning

Onsite FAT/SAT support with parameter validation, safety proof testing, and documentation handoff.

05

Lifecycle optimization

Remote monitoring, firmware governance, and performance analytics integrated into OEM service offerings.

PLC starter assets

Jump-start engineering and project approvals with packaged documentation.

PLC application template

Includes structured text libraries, HMI screens, and integrated drive parameter import tools.

Available via partnership

Cybersecurity controls matrix

Maps Danfoss PLC features to IEC 62443 requirements with recommended OEM responsibilities.

Download

Lifecycle service catalog

Outlines DrivePro® packages, spare parts strategy, and remote support agreements.

Consultation
Planning a PLC migration?

Co-develop your Danfoss PLC roadmap with us

We will review existing architectures, identify PLC migration paths, and align Danfoss firmware & services to your product roadmap.

Book a PLC workshop See blueprint alignment